P RefStd 1133 v090101.2 en Refining-Standard-Pressure-Safety

P RefStd_1133_v090101.2_EN_Refining-Standard-Pressure-Safety-Valves-Periodical-Inspection.doc

Valid as of: 101101 Pressure Safety Valves, Tank Breather Valves, Periodical Inspection, Testing, Pre Pop Test

Page 1 of 16 Version: 090101.2

OMV Petrom Refining & Petrochemicals all rights reserved

Short Name: 1133_v090101.2 OMV Petrom

Refining Standard

Short Description:

Pressure Safety Valves, Periodical Inspection

This Refining Standard was adopted for Petrom OMV Refining based on OMV Refining Standard 1133_v090101.2 by issuing and releasing of Local Amendment

Subject: Pressure Safety Valves, Tank Breather Valves

Objective: Periodical Inspection, Testing, Pre Pop Test

Target Group: All personnel involved in overhauling of pressure relief valves as Field Engineers Operations department Plant Chiefs Inspection Mechanical maintenance department Valves Responsible Valves workshop Mechanical contractor

Scope of Effectiveness:

The scope of effectiveness is limited to Refining business segment within OMV Petrom Refining.

Authors P-R-P-M-PM P-R-P-M-PM P-R-A-M-PM

Razvan Paraschiv Nicolae Cuciurean Sorin Boiangiu

Responsibles for the content

P-R-P-M-PM P-R-A-M-PM

Nicolae Cuciurean Dan Leu

Approved regarding formal correctness by P-R-R&P-BSPM Felicia Decusara

Verified regarding correctness of content by

P-R-A-M

P-R-P-M Sorin Coltan Stefan Toader

Released by P-R-R&P-BSPM Adrian Mincu

Released by P-R-R&P Dir. Neil Morgan

Organizational Unit Name Date

Notes: 1. In the interests of simplicity and readability the language of this statement is as far as possible gender neutral. Where

applicable, the masculine includes the feminine. 2. Hardcopies of this document may not represent the current applicable standard. Check for latest document on the Refining

Regulation Platform





1. Introduction (see Local Amendment L03) Acc. Betriebssicherheitsverordnung (Germany) [RE01] or Druckgerteberwachungsverordnung (Austria) [RE02] basically safety valves own same inspection periods as static pressure equipment to which they belong to (If not otherwise required, e.g. severe services, impurities such as dirt, coke). (See Local Amendament L03). Safety valves must be inspected

o at periodically specified intervals in concordance with legal regulations and

o in respect to condition, RBI (Risk Based Inspection) programs and functional and process safety.

This standard is applicable to all safety valves + tank pressure relief valves of all OMV sites.

Note: As safety valves represent safety devices against overpressure it is necessary for the operations department to define measures

o against any overpressure or

o relief of any products into environment during performance of these inspection works.

Scope of work for periodical inspection: o Dismounting + blinding of adjacent pipes o Pre pop testing o Cleaning (see Local Amendment L03) o Disassembling o Verification of condition (see Local Amendment L03) o Repair if required o Reassembling o Check of relief pressure and final approval o Remounting o Final approval

In addition pre pop tests have to be performed: o Within 1 revision period 25% of valves shall be pre pop tested. o After 4 revision periods 100% of valves have to be pre pop tested. o Valves in severe services where heat tracing is required (e.g. valves in bitumen service)

shall normally not pre pop tested except otherwise indicated.





If severe fouling, dirt and/or residues are found after dismounting, pre pop test has to be refused. Test intervals have to be redefined or other protective measures have to be taken. (see Local Amendment L03)

2. Regulatory Content The Regulatory Content of this document is structured as follows:

Table of Contents 2.1 Responsibilties ...................................................................................................................... 4 2.2 Administration, due date monitoring, initiation.................................................................. 6 2.3 Inspection + servicing of safety valves............................................................................... 6 2.3.1 Dismounting ......................................................................................................................... 6 2.3.2 "Incoming test", Pre-pop test (As Received Test) if applicable............................................ 7 2.3.3 Disassembly / Visual inspection........................................................................................... 7 2.3.4 Service / Reassembly .......................................................................................................... 8 2.3.5 Setting the relief pressure .................................................................................................... 8 2.3.6 Inspection Intervals ............................................................................................................ 10 2.4 Special note for inspection + servicing of tank breather valves (pressure and vacuum relief valves)....................................................................................................................... 11 2.4.1 Inspection and maintenance in PLANT.............................................................................. 11 2.4.2 Inspection and maintenance in WORKSHOP.................................................................... 12 2.5 Inspection outside refinery and/or in turnarounds .......................................................... 13 2.6 Remounting.......................................................................................................................... 13 2.7 Installation check................................................................................................................. 13 2.8 Warm pressure setting check............................................................................................. 13 2.9 Documentation..................................................................................................................... 13





2.1 Responsibilties (see Local Amendment L03) Responsibilities for realization of this standard are outlined as follows:

A) Maintenance Inspection Department incl. RBI B) Maintenance Field Engineering C) Operations department D) Valve Responsible in Maintenance Mechanical Equipment Department E) Process Safety Site Leader F) Turnaround Planning Team

A B C D E F Administration of PSV valve data bank Due date monitoring + announcement to field engineering Fix 25% scope of valves to be pre pop tested. (see Local

Amendment L03)

Define valves which are within special attention of RBI (Risk Based Inspection) scope(see Local Amendment L03)

Acceptance of relief pressure test Final acceptance of relief pressure test after reinstallation in plant

(Warm test, e.g. boiler vessel PSVs)

Initiation, planning + scheduling (see Local Amendment L03) Initiation, planning + scheduling for turnaround Shut down plant and/or provide plant for inspection of PSV / PRV

within due dates.

If heat tracing system exists: Commissioning and check of proper functioning of heat tracing system after remounting of valve in plant (E.g. valves in bitumen service, sulfur service, ammonia salts).

Initiate works according order from field engineering, spare parts management, contractor qualification (see Local Amendment L03)

Dismounting, blinding of adjacent pipes and remounting. Technical verification of valve (+ of adjacent inlet + outlet pipework

acc. API 576, chapter 6.2.6.)

Technical inlet + outlet pipework acc. API 576, chapter 6.2.6.) Technical administration/documentation of PSV valve data bank Definition together with inspection department, field engineering

and process safety responsible about revised inspection periods according findings of

pre pop test internal inspection

(see Local Amendment L03)





Valve repair protocol acc. subdocument [TA01, TA 02] (pre pop test results, repair report, acceptance test documentation)

Final installation check after remounting in plant Final installation check of flanges to adjacent pipework according

flange quality management procedure

o Transfer of PSPI (Process Safety Performance Indicators) datas to process safety site leader:

o number of valves become due + planned o number of valves inspected o thereof number of valves with:

pre pop test declined pre pop test failed severe wear

on a quarterly basis of respective year. (see Local Amendment L03)

Develop + compile PSPI data and inform head of o operations department o maintenance department

in order to deduct measures.

Transfer of degradation findings within valve inspections to RBI responsible in inspection department

A B C D E F





2.2 Administration, due date monitoring, initiation To be able to run a program for testing of safety valves in concordance with the legal regulations an IT-assisted file must be kept by Maintenance Inspection or Mechanical Equipment department. Inspection Department or and Mechanical Equipment Department announces and reminds in written to maintenance Field Engineering all respective due dates. Field Engineering has to fix together with Operations Department when to perform respective activities. Field Engineering will initiate work according this standard and mechanical workshop has to perform respective activities. For turnarounds: If any activities have to be performed within turnarounds Field Engineering has to forward necessary information to Turnaround Planning Team. Turnaround Planning Team will initiate work according this standard and mechanical contractor has to perform respective activities.

2.3 Inspection + servicing of safety valves (see Local Amendment L03) Foreword Condition of disassembled safety valve is evaluated for potential

o mechanical and / or

o corrosion-related damage. Adjacent pipework (Inlet / Outlet) has to be verified acc. [RE03] API 576, chapter 6.2.6. too. As a result of this it is possible to determine whether safety valve can still be used or whether it has to be replaced by a new one. ([AM05] MRS-RP-6050-104 Erstabnahme von Sicherheitsventilen) Relief pressure setting of safety valve must also be checked. An acceptance and sealing with lead (by Notified Body if within their scope of responsibility) must be recorded in repair protocol. All work has to be performed in concordance with "Technical Conditions for Frame Contract Valve Service [AM01], [AM02], [AM03]. (see Local Amendment L03)

2.3.1 Dismounting (see Local Amendment L03) o Check whether tag number of safety valve is attached also to adjacent pipework. If not apply

tag. (see Local Amendment L03) o Dismount valve o Check adjacent pipework for corrosion, erosion and dirt. If unusual corrosion, deposits or

any abnormal conditions are discovered Valve Responsible + Inspection Department must be involved.

o Close adjacent pipes with blind flanges + gaskets acc. pipe class.





2.3.2 "Incoming test", Pre-pop test (As Received Test) if applicable Test must be carried out as follows:

o Inspection whether lead seal is undamaged. o Check proper seat of lifting device cap. o Check whether valve is extremely fouled and dirty. If applicable and valve seat might be

damaged do not carry out pre-pop test and redefine test intervals; analyze the cause of fouling (coke, polymers, etc) and implement measures for avoidance or reduction.

o Mount valve on test bench, slowly increase pressure, the pressure at which the valve relieves is the cold differential test pressure (CDTP) = pre-pop pressure

o If valve relieves at more than +10% above the setting pressure, repeat the test. If now valve relieves below +10% check seat for deposits or unproper seat conditions (sticking).

o If valve relieves again at more than +10% above setting pressure valve setting was originally in error or changed during operation.

o If valve does not open up to 150% of setting pressure (do not increase the pressure above 150% of the setting pressure!), disassemble valve and investigate cause.

o If valve relieves below setting pressure valve setting was originally in error or changed during operation or valve spring is weakened.

o The pressure at which the valve has first relieved is recorded as the pre-pop pressure (Evaluation as per section 2.3.6 paragraph II Adapting test interval).

o Leakage test of bellow with 3bar (safety valve mounted at outlet side on test bench)

2.3.3 Disassembly / Visual inspection After pre-pop- test safety valves are disassembled and cleaned with appropriate cleaning method (normally hydroblasting) prior to visual inspection. Visual inspection is carried out by experienced, qualified craftsmen. If unusual corrosion, deposits or any abnormal conditions are discovered Valve Responsible must be involved. Attention must be paid to following points

o Flanges: Corrosion, roughness, general condition of sealing surface o Spring: Corrosion, cracks o Bellows: Corrosion, cracks, deformation o Adjusting bolts: Locking (Counterlock) o For API-Valves: Record blow down ring position if applicable. o Inlet and outlet: Corrosion, erosion, impurities o Surfaces / Guide surfaces: Corrosion, mechanical damage o Housing: Visual inspection of wall, determination of wall thickness, dye penetrant test if

applicable or if required by RBI (Risk Based Inspection) program.





2.3.4 Service / Reassembly Worn parts must be reconditioned or replaced. Spare parts shall be from original manufacturer. Valve seats and stem cone are machined and/or lapped. Special attention must be paid to ensure that parts are not mixed up during the reassembly. Positioning of adjustment rings must be in concordance with manufacturer's data. New seals must be used. Special attention must be paid to the operability of lifting device lever and seal of lifting device lever. Pre-tensioning of spring. Note: In the case of additionally-loaded or pilot-controlled safety valves control elements must be serviced and inspected according manufacturer's service manual.

2.3.5 Setting the relief pressure (see Local Amendment L03) Safety regulations "Testing Safety Valves" must be followed when commissioning test bench. Safety valve responsible has to be informed before pressure setting is performed. Safety valve responsible personally approves pressure setting test or informs notified body for approval. (see Local Amendment L03).

Setting the relief pressure on test bench "cold". o The test pressure has to be slowly increased up to setting pressure. o If the required setting pressure is exceeded by more than 10% during this, test pressure has

to be reduced and spring pre-tensioning has to be reduced. Repeat the process.

After setting pressure has been determined nuts have to be locked and valve has to be tested again, at least two times, in order to test accuracy of setting. The following tolerances are permitted according to EN ISO 4126-1:

o Pressures < 3bar max. 0.15 bar o Pressures > 3bar max. 3 % o After this, the test pressure has to be reduced to 90% of the setting pressure and leakage

test is conducted (bubble test at outlet side). o The setting values, free thread length and setting pressure must be kept in repair report by

the test technician. The test date must also be entered in the electronic database. o Correspondence of valve identification with setting pressure indicated at outlet or type plate

must be checked.





Checking of safety valves in the plant Checking pressure setting value in plant shall be basically avoided. Increased safety risk, contamination or even damage of valve seats are negative factors. If a test in plant is necessary the use of suitable approved test methods (lifting device and pressure sensors) is necessary. Compliance with the safety regulations, system approvals and analysis of the effects on the operation of the system are mandatory for this. Risk analysis is mandatory.

Safety valves with additional pneumatic load In case of safety valves with pneumatic additional load in process plants, the control units must be inspected annually for relief pressure and functioning in the presence of notified body. Those test must be documented by recording instruments. The safety valves are tested or serviced according service intervals as per 2.3.6 Heat tracing of control box has to be checked too.

Boiler safety valves Boiler safety valves as well as safety valves in high-pressure and low-pressure steam lines with pneumatic additional load must be inspected annually in the presence of notified body. Test for functioning and relief pressure comprises both the control unit as well as the safety valve and must be documented using recording instruments. Heat tracing of control box has to be checked too.

Pilot operated safety valves Safety valves controlled by their own media (e.g. in heat and power plant) must be inspected annually in presence of notified body. The test for functioning and relief pressure of control valves (impulse valves) must be documented by recording instrumentation. The main valve is serviced as part of the service intervals according to 2.3.6





2.3.6 Inspection Intervals (see Local amendment L03) I) Basic inspection interval Safety valves are assigned to major static pressure equipment which they have to protect against overpressure. Check intervals are defined in national laws. (see Local Amendment L03) Particularly in the case of pilot-controlled and additionally-loaded safety valves, special attention must be paid to the manufacturer's data, especially in respect to the durability of wearing parts and testing of the control equipment.

II) Adapted test interval Records of periodical inspections are important information for definition of future intervals. In addition to this ambient conditions must also be taken into consideration. Test intervals may be adapted in relation to results of pre-pop test, verification of internals and category of protected equipment.

Intervals are adapted by Valve Responsible together with o Inspection Department o Field Engineering o Process Safety Responsible

according following procedure: a) Deviation of pre-pop test pressure to setting pressure 10% If deviation of pre-pop test to setting pressure is not more than 10%, this is regarded as within the acceptable range. b) Deviation of pre-pop test pressure to setting pressure > 10% 50% If deviation of pre-pop test to setting pressure is larger than 10% but within max. permissible pre-pop test pressure (max. 50% of the setting pressure)

o Root cause based action: Clear and direct cause has to be identified and corresponding repair measures have to be fixed.

If not possible o Safety target based action: Test interval might be adapted. If the test interval is shortened,

the assigned risk category must be considered again. c) Deviation of pre-pop test pressure to setting pressure > 50% If deviation of pre-pop test pressure to setting pressure is larger than 50% an analysis and measures for improvement of situation must be implemented. These are typically:

o Root cause based action: Clear and direct cause has to be identified and corresponding repair measures have to be fixed as

o Basic materials of safety valve must be changed (Material compliance) o Change to another type of safety valve (Design compliance) o Installation of rupture disk in front or behind of safety valve (Impact compliance)

o Safety target based action: Significant reduction of check interval.





2.4 Special note for inspection + servicing of tank breather valves (pressure and vacuum relief valves)

Tank breather valves are normally designed as deadweight loaded. They are in permanent operation and tend to get stuck or jam. Periodical inspections can verify this. If the outside temperature falls below freezing point, additional checks are necessary in order to ensure that discs do not stick due to icing. If applicable arrester screens shall be removed in cold seasons. The intervals and service scope "maintenance in plant" or "maintenance in workshops" to be defined by

o valves responsible together with

o inspection department and

o process safety responsible and

o operations chief of plant on the basis of vendor recommendation, storage product, composition, process parameters, environmental impact, experience and findings from last checks. Check period can vary from monthly to yearly. All maintenance activities on those valves have to be recorded in repair protocol and in electronic database.

2.4.1 Inspection and maintenance in PLANT (see Local Amendment L03) Inspection in plant is only permitted if tank is free of any pressure and parameters are constant (no feed, no effluent). Basically vendor maintenance manual has to be followed accordingly. Minimum program is as follows:

o Inspection of outlet pipe whether any deposits or plugging is existing o Removal of valve upper part and inspection of discs for operability o Check seats for adhesion and leakages o Check inlet screen (flame-arrester-filter) (corrosion, fouling, mech. damage), if necessary

replace. o Check of liquid load of diaphragm for overpressure + underpressure side acc. valve data

sheet (Level, density), if there are any deviations check cause, eventually shorten inspection interval.

o Check proper functioning of heat tracing if applicable. o Use only antistatic towels for cleaning in order to avoid explosion risk.

(see Local Amendment L03).





2.4.2 Inspection and maintenance in WORKSHOP Dismounting + remounting is only permitted if tank parameters are constant. Basically vendor check + service recommendation has to be followed. Minimum program is as follows:

o Inspection of inlet + outlet pipe whether any deposits or plugging is existing o Check of liquid load of diaphragm valve type (Level, density), if there are any deviations

check cause, possibly shorten inspection interval. o Check diaphragm: Cracks, deformations, flexibility, material condition o Adhesion (sticking): Inspection of discs. If any disc sticks it is necessary to analyze what

product causes impact to sealing material and disc. If necessary replace o Check and service disc: If it is visible that weight of cone has changed (corrosion,

unauthorized intervention,) disc weight must be checked. If necessary, material must be added or removed (take care of operability). If this is not possible disc must be replaced.

o Check inlet screen (flame-arrester-filter) (corrosion, fouling, mech. damage), if necessary replace.

o Seat: Inspect, clean and recondition (grind) o Check surface of seat, regrind or replace seat. o Check protective grating, if necessary replace o Supports: check and lubricate o Check paintwork and, if damaged or significantly attacked, repaint o Check valve cap and if necessary replace o Check bolts and nuts and if necessary replace o Use only OEM (original equipment manufacturer) spare parts o Make sure that all parts are properly dried. o Fill liquid load acc. valve data sheet (Type of liquid, level, density) o Reassembling and final test for functioning and operability o Reinstallation: Plump (use bubble level) valve in absolute vertical / horizontal position o After reinstallation check proper functioning of heat tracing if applicable.

Vendor installation, commissioning and maintenance manual has to be followed accordingly.





2.5 Inspection outside refinery and/or in turnarounds If safety valves are inspected by contractors outside refinery or within turnaround program workflow cited under 2.2.2 must be carried out by contractor. Valve Responsible has to ensure quality by performing quality management audits + reaudits. All inspection test protocols have to be forwarded to valve responsible on a daily basis.

2.6 Remounting Only after finishing protocol safety valves may be delivered into plant for reinstallation shortly before reinstallation. It is not permitted to store safety valves in plant waiting for reinstallation. Transport must be performed in upright position. Valves have to be secured against shocks and fall. Flange bolting activities have to be performed acc...(see Local Amendment L03) [AM04] OMV-Burghausen, BHB Band IV, 4.5.14, Betriebshandbuch QS Flanschverbindungen + QS-Protokoll.

2.7 Installation check After notification that safety valves have been installed Valves Responsible inspects proper reinstallation on the basis of

o Labelling (stamping in the valve flange) o P&ID o Existing lead seal for flange quality check o Blocking bolts not active

If reinstallation inspection has been carried out without complaint, notification will be made to Field Engineering (for turnaround to Turnaround Planning Team).

2.8 Warm pressure setting check Warm pressure setting on site (insofar as indicated) to be initiated by Valve Responsible and carried out in presence of Notified Body. Recording and operational readiness notification must be made by Valve Responsible to Field Engineering.

2.9 Documentation Pre pop test results, checks & repairs, acceptance test of the setting or acceptance data are written down in respective PSV Check, Repair + Acceptance Test Protocol as template [TA01].

All documents to be filed in dynamic equipment department. All data to be transferred into electronic data bank by Valve Responsible.





3. Terms and Abbreviations Terms

Term Definition Valve Responsible Responsible person for valves within dynamic equipment department

Abbreviations

Abbreviation Definition PSV Pressure Safety Valve PRV Pressure Relief Valve PSPI Process Safety Performance Indicators RBI Risk Based Inspection

4. Keywords (Search Criteria, Search Terms) Refining Standard, PSV, PRV, Pre Pop Test, Valve Responsible, Setting Pressure, PSV Check, Repair + Acceptance Test Protocol, CDTP

5. Local Amendments, Sub-Documents & References, Templates Local Amendments [LA01] Amendament Local MRS [LA02] Amendament Local MRB [LA03] Amendament Local Rafinariile Petrom ( Petrobrazi si Arpechim)

[AM01] OMV-Schwechat , Technischen Bedingungen fr den Rahmenkontrakt Armaturenservice [AM02] OMV-Burghausen, berholungsarbeiten an Sicherheitsventilen (Instandhaltungsleistungen Elektro-,Mess- u. Regeltechnik) [AM03] OMV-Burghausen, Rahmenvertrag Mechanische Dienstleistungen [AM04] OMV-Burghausen, BHB Band IV, 4.5.14, Betriebshandbuch QS Flanschverbindungen + QS-Protokoll [AM05] OMV-Schwechat , MRS-RP-6050-104 Erstabnahme von Sicherheitsventilen

Referencies (see Local Amendment L03). [RE01] Betriebssicherheitsverordnung (Germany) [RE02] Druckgerteberwachungsverordnung (Austria) BGBl. I Nr. 136/2001 [RE03] API 576 Inspection of pressure relieving devices Templates [TA01] RefStd_1133_T01_v090101 PSV, Pressure Safety Valves, Check, Repair + Acceptance Test Protocol [TA02] RefStd_1133_T02_v090101 PRV, Tank Pressure Relief Valves, Check, Repair + Acceptance Test Protocol





6. Obsolete Regulations Date Comment 20.02.2008 MRS-RP-6050-103 Thema: und Tankschutzarmaturen

7. Amendments from Previous Versions Date Comment none

P RefStd 1133 v090101.2 en Refining-Standard-Pressure-Safety

Documents

Transcript of P RefStd 1133 v090101.2 en Refining-Standard-Pressure-Safety